Automated Composite Ply Stacking via Parallel Plane Layup
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Solution Overview
Problem
Current automatic layup systems for composite materials are cumbersome due to labor-intensive and repetitive handling of composite plies, which limits efficiency and flexibility in forming complex stacks.
Innovation Solution
An automatic layup system comprising a layup tool and stacking assemblies that move in parallel planes, allowing for the precise placement and stacking of composite plies without manual handling, using a support structure to hold composite sheets and positioning tools to separate and place plies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated tape laying machines are used to lay up composite plies, then automation is improved, but the system becomes cumbersome and labor-intensive handling remains
Solution Approach 1:
The patent replaces manual mechanical handling of composite plies with an automated positioning system. The layup tool moves automatically to positions aligned with stacking assemblies, and composite plies are automatically separated and placed by the stacking assemblies, eliminating the need for labor-intensive manual handling while maintaining precise placement control.
Solution Approach 2:
The system enables self-service operation where the layup tool and stacking assemblies work autonomously. The layup tool automatically positions itself relative to the stacking assemblies, and the stacking assemblies automatically separate and place composite plies without requiring external manual intervention, making the system operate independently once initiated.
2Productivity
If manual handling of composite plies is used, then flexibility in handling is maintained, but productivity and efficiency are reduced
Solution Approach 1:
The system maintains continuous productive action by having the layup tool continuously move to aligned positions with stacking assemblies, which continuously separate and place composite plies. This eliminates idle time and interruptions associated with manual handling, maintaining a continuous flow of composite ply placement that maximizes manufacturing efficiency.
Solution Approach 2:
The stacking assemblies perform preliminary separation of composite plies from sheets before placement occurs. This preliminary action prepares the composite plies in advance, allowing for rapid sequential placement without delays for manual separation and positioning, thereby reducing overall placement time and increasing productivity.
3Ease of operation
If automated systems are implemented, then labor intensity is reduced, but system complexity increases
Solution Approach 1:
The stacking assemblies serve multiple functions: they hold composite sheets, separate individual composite plies from the sheets, and automatically place the plies onto the layup tool. This multi-functionality reduces the need for separate dedicated components for each operation, thereby reducing overall system complexity while maintaining automation and reducing labor intensity.
Solution Approach 2:
The system uses a vertical arrangement where stacking assemblies are positioned above the layup tool in a parallel plane configuration. The layup tool moves horizontally to aligned positions while stacking assemblies move vertically to place plies. This spatial arrangement in different dimensions allows automated operation with simpler individual component designs compared to a fully integrated horizontal system.
Data Source
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Figure 6(a)~6(d)
AI summary
A method and an automatic layup system for making a stack of a plurality of composite plies are presented. The automatic layup system includes a stacking assembly located in a first plane and a layup tool located in a second plane parallel to the first plane. The stacking assembly and the layup tool are movable towards each other. The method includes the steps of (a) providing one or more composite sheets between the layup tool and the stacking assembly, (b) generating a first composite ply from the one or more composite sheets, (c) placing the first composite ply on the layup tool by the stacking assembly by bringing the stacking assembly and the layup tool close to each other, and (d) repeating the steps (b) and (c) for generating and placing a second composite ply on the first composite ply, which is placed on the layup tool.